Our Roastmaster measures the exact amount of green beans to be roasted. Some of our blends’ recipes have up to 7 different origin coffees. All 25 of the countries we purchase coffee from have different flavors and characteristics that contribute to a uniquely wonderful tasting coffee.
We roast our coffee in a state of the art 60 kilo roaster equipped with a Roast Profile Computer System. This system controls the gas, roast temperature and roast development time by measuring the coffee roasting. This is done through probes tracking the air, drum surface and bean temperatures.
What does this mean? Our coffee will always be consistently unique and delicious roast after roast.
As the coffee roasts the outer layer of skin begins to peel off of the bean. This is called chaff. A cylinder traps the chaff and is removed from our finished coffee. We only package 100% coffee in every bag we produce.
We installed an afterburner also known as a Thermal Oxidizer. This unit burns off smoke that is produced during the roast process – no bellows of smoke outside our building, but there is still that wonderful smell of coffee throughout the place from our grinder!
Once the beans have been roasted to reach the finished temperature the roaster door opens and out come the hot, roasted beans. We use a large cooling tray and a refrigerated airline to cool the beans and stop the roasting process. No quenching here! (The process some roasters use by spraying water on the roasted beans to stop the roasting process.) Quenching adds a percentage of the lost weight back into the coffee beans. The real problem is the added moisture and oxygen to the beans – coffees’ worst enemies!
Now that the beans have cooled they are vacuumed into our de-stoning hopper. The beans are light after roasting and are easily moved into the hopper. Anything that is not coffee that was shipped inside the burlap bags are caught in the screen, trapped by the magnets or fall to the bottom of the tray. We call these the souvenirs sent from the farmers. They are mostly stones and if left with the coffee they would cause problems in coffee grinders.
Coffee is like a sponge and absorbs odors. Because of this trait, we built a special room with a positive airflow to the outside of the building – preventing the flavors from seeping into the rest of the facility. In this room are our kosher flavorings, flavor mixer, flavor grinder, weigh/fill machine and fractional package machine – all are dedicated to the flavoring process.
We have several different techniques to package our coffees after roasting. Our beans are packed in 2-pound and 12-ounce bags. All of our bags have one-way valves allowing the natural coffee gases to escape and prevent air from getting into the bag. They are individually labeled and packed by hand.
Whole beans are packed in 2-pounds since most grinders can’t hold more than 2-pounds at a time. 5-pound bags increase waste. When there are excess beans the 5-pound bags are rolled up – allowing the coffee to be exposed to air. Air on coffee makes coffee stale. And let’s not forget that open, rolled 5-pound bags spill the beans!
Our fractional, ground coffees are packed by a form and seal machine. The machine fills a fraction pack bag with the proper weight of ground coffee, infuses Nitrogen to displace any oxygen, and seals the bag shut. We have a Nitrogen Generating machine to ensure our packaging will consistently have less than 2% oxygen.